31

450

V

This is how it works:

A constant voltage is applied to the fuel composition sender by the engine control unit.

Water level OK

The contact pins are surrounded by diesel fuel. Because diesel fuel has a low level of conductivityconductivity, there is a high signal response. In this way, the engine control unit detects that the water level is OK and sends the information to the dash panel insert. The preglow warning lamp K29 does not light up.

Water level not OK

The contact pins are surrounded by water. Because water has a high level of conductivity, there is a low signal response. The engine control unit detects that the water level is too high and sends the information to the dash panel insert. The glow period warning lamp K29 will be actuated in the dash panel insert and it will flash. Flashing indicates a fault in the engine manage-ment system. The engine should be checked in a specialist workshop.

304_050

304_055

450

V

Water

Input signal CAN drive train databus

EarthPositive

Fuel

Wiring colour key

Contact pins

32

Actuators

Unit injector solenoid valves, cylinders 1 - 6 N240 … N244 and N245, Unit injector solenoid valves, cylinders 7 - 10 N303 … 306

The unit injector solenoid valves are secured to the unit injector bodies by union nuts. The solenoid valves are actuated by the engine control units. These control start of delivery and the amount of fuel injected.

As soon as a unit injector solenoid valve is actuated by the engine control unit, the valve needle is pushed onto its seat by the magnetic coil and this closes the path of fuel to the compression chamber of the unit injector. Thereafter, injection will start.

The amount of fuel injected is determined by the actuating period of the solenoid valve. As long as the unit injector solenoid valve is closed, fuel will be injected into the combustion chamber.

Effects of failure

If a unit injector solenoid valve should fail in its function, the engine will not run smoothly and performance will be impaired.

The unit injector solenoid valve has two safety functions. If the valve stays open, pressure cannot be built up in the unit injector. If the valve stays closed, the compression chamber of the unit injector can no longer be filled. In both cases, no fuel can be injected into the cylinder.

Engine management

304_022

304_032

Unit injector solenoid valve

Unit injector solenoid valve

33

304_010

304_078

Turbocharger positioning motors V280 and V281 (V10-TDI-engine)

The turbocharger positioning motors are bolted to a bracket beneath the turbocharger. One con-trol unit can be found in each positioning motor.

Task

The positioning motors are actuated by the respective engine control unit via a CAN databus. This improves regulation and fault diagnosis. The improvement is thanks to information about guide vane positioning and detected faults that the engine control units receive. The turbocharger guide vanes are actuated via a rod assembly.

Effects of failure

If the positioning motors fail in their function, charge pressure control is no longer possible. The amount of fuel injected is limited according to the engine speed and engine performance will be impaired.

Charge pressure limitation solenoid valve N75(R5-TDI-engine)

The charge pressure limitation solenoid valve can be found beneath the variable turbocharger.

Task

The charge pressure limitation solenoid valve is actuated by the engine control unit. Vacuum is built up in the vacuum unit for guide vane adjustment depending on the duty cycle.

Turbocharger 1 positioning motor V280

Turbocharger 2 positioning motor V281

Effects of failure

The vacuum unit is filled with atmospheric pressure. Charge pressure is lower as a result and engine performance is impaired.

The turbocharger positioning motor is designed specifically for use with the turbocharger. For this reason, both parts should be only be removed or replaced together.It is critical that reference be made to the workshop manual.

34

Engine management

Exhaust gas recirculation solenoid valves N18 and N213

The solenoid valves for exhaust gas recirculation can be found on the suspension strut domes on each side. The valves are electro-pneumatic.

Task

The valves are actuated with a duty cycle by the engine control unit depending on the map. In this way, the control pressure for the recirculation valve can be set. The cross section of the exhaust manifold is changed in the exhaust gas recirculation valve depending on the control pressure and the amount of recirculated exhaust gas set.

Effects of failure

If the signal fails, exhaust gas recirculation may no longer be possible.

Intake manifold flap motors V157 and V275

The V10-TDI-engine has two electrically adjustable intake manifold flaps and there is one electric motor for each flap. These can be found directly in front of the respective exhaust gas recirculation valve.

Task

– With the electrically adjustable intake manifold flaps, differences between air intake pressure and exhaust gas pressure are generated in certain operating conditions. Effective exhaust gas recirculation is guaranteed thanks to the differences in pressure.

– When the engine is switched off, the flap is closed and the flow of air interrupted. In this way, less air is drawn in and compressed which helps smooth run-down of the engine.

304_012

Effects of failure

In case of failure, effective exhaust gas recirculation is no longer possible.

304_011

Exhaust gasrecirculation valve N18

Exhaust gasrecirculation valve 2 N213

Intake manifold flap motor V157

Intake manifold flap motor 2 V275

Exhaust gasrecirculation valve

35

304_048

304_048

Effects of failure

If the changeover valve fails in its function, the intake manifold flap will stay in the open position. If this happens, strong jolts will be noticeable when the engine is switched off.

Effects of failure

If the changeover valve fails in its function, the exhaust gas cooling flap will stay in the closed position and the exhaust gas will no longer be cooled. This can lead to an increase in nitrogen oxide emissions.

Intake manifold flap changeover valve N239(R5-TDI-engine)

The intake manifold flap changeover valve can be found on the right-hand suspension strut dome.

Task

When the engine is switched off, the intake manifold flap changeover valve is actuated by the engine control unit. Following this, the intake manifold flap is closed and the flow of air interrupted. In this way, less air is drawn in and compressed and the engine will run down smoothly as a result.

EGR cooler changeover valves N345 and N381 (Phaeton only)

The exhaust gas recirculation cooler changeover valves can be found in the vicinity of the exhaust gas recirculation cooler.

Task

The changeover valve is actuated by the engine control unit depending on the temperature. It clears the path from the vacuum pump to the membrane valve, the exhaust gas cooling flap is actuated and the path through the cooler is cleared.

36

Engine management

Exhaust gas recirculation cooler (Phaeton only)

The V10-TDI-engine in the Phaeton is equipped with independent coolers for the exhaust gas recirculation system.

The pneumatically controlled flaps for exhaust gas cooling allow activation of the cooler from a coolant temperature of 50

o

C.

304_014

304_031

Cooler for exhaust gas recirculation

Vacuum unit

Cooler for exhaust gas recirculationTo valve

for exhaust gas recirculation

From exhaust manifold

From exhaust manifold

Coolant connection Coolant distribution to switch unit with flap for exhaust gas cooling

37

Without exhaust gas cooling

304_025

304_037

With exhaust gas cooling

The engine and the catalyst are cold. The

exhaust gas cooling flap

is closed. The exhaust gases are directed past the cooler and are therefore not cooled. In this way, the engine will reach its effective operating temperature quickly.

The engine and the catalyst have reached effective operating temperature. The

exhaust gas cooling flap

is open. The exhaust gas is directed through the cooler and is therefore cooled. The combustion temperature is reduced due to the cooled exhaust gases and a greater amount of exhaust gas can be recirculated. In this way, fewer nitrogen oxides are produced and carbon build-up is avoided.

Cooler for exhaust gas recirculation

To valvefor exhaust gas recirculation

Coolant

Coolantconnection Flap for

exhaust gas cooling

From exhaust manifold

From exhaust manifold to cooler through flow

To valvefor exhaust gas recirculation

Flap for exhaust gas coolingCoolant

38

Engine management

– Fuel pump G23 with fuel gauge sender G and a suction jet pump can be found in the main chamber of the fuel tank.

– Fuel pump G6 with fuel gauge sender 3 G237 and a suction jet pump can be found in the secondary chamber of the fuel tank.

304_049

Actuation of both electrical fuel pumps is done in parallel sequence via the fuel pump relay J17.

Suction jet pump 1 draws fuel from the main chamber into the presupply reservoir of fuel pump G6 and suction jet pump 2 pumps out the secondary chamber into the presupply reservoir of fuel pump G23. Both suction jet pumps are driven by the electrical fuel pumps.

Effects of failure

If one pump fails, engine performance will be impaired due to a restriction in the amount of fuel supplied.

The maximum speed is unattainable and the engine will not run smoothly at high revs.

Fuel pumps G6 and G23

Both electrical fuel pumps are installed in the fuel tank.

Fuel pump G6(presupply pump)

Fuel pump G23

Suction jet pump 2Suction jet pump 1

Fuel gauge sender 3 G237

Fuel gauge sender G

39

304_016

304_029

A more detailed description of the map-controlled engine cooling can be found in Self-Study Programme No. 222 "Electronically Controlled Cooling System".

Thermostat for map-controlledengine cooling F265

The thermostat for map-controlled engine cooling can be found in the coolant distribution housing. It has the task of switching between the large and small coolant circuits. To do this, it is actuated by the engine control unit according to the engine operating conditions. Maps are stored in the engine control unit which contain temperature specifications depending on the engine load.

Map-controlled engine cooling has the advantage that the coolant temperature can be adapted to the current operating conditions of the engine. This helps to reduce fuel consumption in the part-throttle range and also exhaust gas emissions.

Expanding material element

Plunger pin

Spring

Resistance heater

Coolant distribution housing

Coolant distribution housing

40

Engine management

J623

M

J496

V51

304_027

304_067

J623 Engine control unit 1J496 Additional coolant pump relayV51 Continued coolant circulation pump

Additional coolant pump relay J496, Continued coolant circulation pump V51

The continued coolant circulation pump can be found on cylinder bank 1 on the vibrationdamper side. Due to the high working current, the pump is actuated via a relay.The additional coolant pump relay is installed in the electronics box which can be found in the plenum chamber.

Task

When the engine is switched off, the continued coolant circulation pump will remain activate for a maximum of 10 minutes. In this way, controlled cooling of the engine is achieved.

Effects of failure

If the replay or the continued coolant circulation pump fail, continued coolant circulation is no longer possible. If the relay is defective, a fault will be stored. A defective pump cannot be detected.

Electrical actuation

The engine control unit actuates the continued coolant circulation pump via the additional coolant pump relay.

Continued coolant circulation pump V51

Vibration damper

41

J623

M

J445

V166

304_009

304_068

Fuel cooling pump relay J445 and fuel cooling pump V166 (Touareg)

The fuel cooling pump can be found on cylinder bank 1 on the vibration damper side.The pump is actuated via a relay due to the high working current.The relay for the fuel cooling pump is installed in the electronics box which can be found in the plenum chamber.

Task

The engine control unit actuates the fuel cooling pump relay at and above a fuel temperature of approximately 70

o

C. The engine control unit sends a working current to the fuel cooling pump and the fuel cooler is then surrounded by coolant. Fuel temperature will drop.

Effects of failure

If the fuel cooling relay or fuel cooling pump fail, fuel will no longer be cooled. The fuel tank and the fuel gauge sender could become damaged.A defective relay is stored as a fault. A defective pump cannot be detected.

Electrical actuation

The fuel cooling pump is actuated via fuel cooling pump relay J445 by engine control unit 1 J623.

Fuel cooling pump V166

Vibration damper

J623 Engine control unit 1J445 Fuel cooling pump relayV166 Fuel cooling pump

42

Engine management

Right solenoid valve for electro-hydraulic engine mounting N145 (Phaeton)

The V10-TDI-engine in the Phaeton features hydraulically dampening engine mountings.

These engine mountings reduce the transmission of engine vibration to the body and in doing so provide a high level of driving comfort.

304_041

304_040

Left engine mounting

Engine carrier

Right engine mounting

Left engine bracket

Right engine bracket

Right solenoid valve for electro-hydraulic engine mounting N145

43

This is how it works:

The hydraulically dampening engine mountings are actuated pneumatically via solenoid valve N145. The engine mountings reduce vibrations that are transmitted to the body by the engine across the entire throttle range.

The road speed and engine speed are used as input signals.

304_042

More detailed information about the function of the engine mountings can be found in Self-Study Programme No. 249 "Management of the W8 Engine in the Passat".

Control unit for ABS with ESP J104 (road speed)

Engine speed sender G28

Right solenoid valve for electro-hydraulic engine mounting N145

Engine mounting, right

Engine mounting, left

Engine control unit 1 J623

From vacuum pump

44 45

M M M

N213

C

N381

J623

30

15

6 7 8 9

J624

N240 N241 N242 N243 N244 N245 N303 N304 N305 N306G81 G248 G447 G299

43 1 2

J317

J689

λ

G108 Z28

λ

G39 Z19

MH

V275

B

M

V157

M

V280 V281

N18

C

F265

M

E F

M

J496

V51

J445

V166

G62 G83 G133

+

G40G31 G42

F

G28 F60/F8 G79

J17

A

G23

N145

H

B

G

G70

30

15

FF47

C

J495

D

A

J52

55

E

Q10...Q14 Q15...Q19

1

2

N345

D

G6

G246

G

Engine management

Additional signal

CAN drive train databus (high)CAN drive train databus (low)Radiator fan output stage 1Radiator fan output stage 2Coms lead (diagnosis connection)Cruise control system switch (ON/OFF)Road speed signalAlternator terminal DFMStarter relay J...

Key

F Brake light switch F8 Kick-down switch F47 Brake pedal switch F60 Idle switch F265 Thermostat for map-controlled engine

cooling

G6 Fuel pump (presupply pump)G23 Fuel pumpG28 Engine speed sender G31 Charge pressure senderG39 Lambda probeG40 Hall sender G42 Intake air temperature sender G62 Coolant temperature senderG70 Air mass meterG79 Accelerator pedal position senderG81 Fuel temperature senderG83 Coolant temperature sender

radiator outletG108 Lambda probe 2G133 Fuel composition senderG246 Air mass meter 2G248 Fuel temperature sender 2G299 Intake air temperature sender 2G447 Charge pressure sender 2

J17 Fuel pump relayJ52 Glow plug relayJ317 Voltage supply relay - term. 30J445 Fuel cooling pump relayJ495 Glow plug relay 2J496 Additional coolant pump relay J623 Engine control unit 1J624 Engine control unit 2J689 Voltage supply relay 2 term. 30

N18 Exhaust gas recirculation valve N145 Electro-hydraulic engine mounting

solenoid valve N213 Exhaust gas recirculation valve 2 N240 Unit injector solenoid valves ... N245 N303 ... N306 N345 EGR cooler changeover valveN381 EGR cooler changeover valve 2

Q10 Glow plugs... Q19

V51 Continued coolant circulation pump V157 Intake manifold flap motor V166 Fuel cooling pump V275 Intake manifold flap motor 2 V280 Turbocharger 1 positioning motor V281 Turbocharger 2 positioning motor

Z19 Lambda probe heating Z28 Lambda probe heating 2

123456

789

ABCD

Connections within functional diagramEFGH

Functional diagram for V10-TDI-engine

304_001

44 45

M M M

N213

C

N381

J623

30

15

6 7 8 9

J624

N240 N241 N242 N243 N244 N245 N303 N304 N305 N306G81 G248 G447 G299

43 1 2

J317

J689

λ

G108 Z28

λ

G39 Z19

MH

V275

B

M

V157

M

V280 V281

N18

C

F265

M

E F

M

J496

V51

J445

V166

G62 G83 G133

+

G40G31 G42

F

G28 F60/F8 G79

J17

A

G23

N145

H

B

G

G70

30

15

FF47

C

J495

D

A

J52

55

E

Q10...Q14 Q15...Q19

1

2

N345

D

G6

G246

G

Engine management

Additional signal

CAN drive train databus (high)CAN drive train databus (low)Radiator fan output stage 1Radiator fan output stage 2Coms lead (diagnosis connection)Cruise control system switch (ON/OFF)Road speed signalAlternator terminal DFMStarter relay J...

Key

F Brake light switch F8 Kick-down switch F47 Brake pedal switch F60 Idle switch F265 Thermostat for map-controlled engine

cooling

G6 Fuel pump (presupply pump)G23 Fuel pumpG28 Engine speed sender G31 Charge pressure senderG39 Lambda probeG40 Hall sender G42 Intake air temperature sender G62 Coolant temperature senderG70 Air mass meterG79 Accelerator pedal position senderG81 Fuel temperature senderG83 Coolant temperature sender

radiator outletG108 Lambda probe 2G133 Fuel composition senderG246 Air mass meter 2G248 Fuel temperature sender 2G299 Intake air temperature sender 2G447 Charge pressure sender 2

J17 Fuel pump relayJ52 Glow plug relayJ317 Voltage supply relay - term. 30J445 Fuel cooling pump relayJ495 Glow plug relay 2J496 Additional coolant pump relay J623 Engine control unit 1J624 Engine control unit 2J689 Voltage supply relay 2 term. 30

N18 Exhaust gas recirculation valve N145 Electro-hydraulic engine mounting

solenoid valve N213 Exhaust gas recirculation valve 2 N240 Unit injector solenoid valves ... N245 N303 ... N306 N345 EGR cooler changeover valveN381 EGR cooler changeover valve 2

Q10 Glow plugs... Q19

V51 Continued coolant circulation pump V157 Intake manifold flap motor V166 Fuel cooling pump V275 Intake manifold flap motor 2 V280 Turbocharger 1 positioning motor V281 Turbocharger 2 positioning motor

Z19 Lambda probe heating Z28 Lambda probe heating 2

123456

789

ABCD

Connections within functional diagramEFGH

Functional diagram for V10-TDI-engine

304_001

46

Self-diagnosis

Diagnosis

On vehicle diagnosis, testing and information systems VAS 5051 and VAS 5052:

– Guided fault finding

*

and– Vehicle self-diagnosis

can be selected.

Operating mode "Guided fault finding"

checks all vehicle-specific control units for stored faults and automatically compiles an individual testing plan based on the results.This plan is carried out in conjunction with ELSA information, such as current flow diagrams or workshop manuals, selected to aid fault finding.

In addition to this, you can also compile your own testing plan. The tests you choose from the selection of functions and components will be added to the testing plan and can be carried out as a diagnostic sequence in any order.

Operating mode "Vehicle Self-Diagnosis"

can be used in the same way as normal but no additional information is available from ELSA.

Service

304_051

304_052

* Not with vehicle diagnosis and

service information system VAS 5052

More detailed information about guided fault finding can be found in chapter 7 of the VAS 5051 operating handbook.

47

Designation Tool

Test box V.A.G 1598/42

Adapter lead V.A.G 1598/39-1

Adapter lead V.A.G 1598/39-2

Workshop Equipment

304_085

304_084

304_083

48

Test your knowledge

Which answers are correct?

One or more answers could be correct.

1. Which special features does Bosch EDC 16 have?

a) It is designed for both single control unit and double control unit concepts.

b) It was designed exclusively for the V10-TDI-engine.

c) It has torque-orientated engine management.

2. Which statements about the V10-TDI-engine are correct?

a) The basic functions for cylinder bank 1 are carried out by engine control unit 1and the basic functions for cylinder bank 2 by engine control unit 2.

b) Information that is received by engine control unit 1 is sent to engine control unit 2 via an internal CAN databus.

c) Engine control unit 1 is responsible for injection and exhaust gas recirculation and engine control unit 2 is responsible for the remaining functions.

3. On the V10-TDI-engine, how are the engine control units allocated to the cylinder banks?

a) The engine control units have different part numbers.

b) The engine control units are coded using VAS 5051.

c) In the connector for engine control unit 2 J624 there is an additional coding link which facilitates allocation.

49

4. On the V10-TDI-engine, Lambda probes calculate the remaining oxygen content in theexhaust gas. In this way, ...

a) the amount of fuel injected is adapted.

b) the amount of nitrogen oxide in the exhaust gas is calculated.

c) the amount of recirculated exhaust gas is corrected.

5. Why is an independent cooler for exhaust gas recirculation used on the V10-TDI-engine in thePhaeton?

a) To prevent excessive warm-up periods of the engine caused by cooled exhaust gases.

b) So that the coolant does not get too hot.

c) To prevent increased carbon dioxide and carbon monoxide emissions during warm-up.

6. What are the advantages of turbocharger positioning motor actuation via the CAN drivetrain databus?

a) More precise regulation is made possible as the position of the guide vanes is detected.

b) More precise fault diagnosis is made possible as detected faults are sent to the engine control units.

c) It is cheaper.

50

7. Which statements about the fuel cooling pump are correct?

a) The fuel cooling pump operates continually while the engine is running.

b) The fuel cooling pump can be found in the Touareg on the V10-TDI-and R5-TDI-engines.

c) The fuel cooling pump is actuated when the fuel temperature is approximately 70 °C.

8. The engine speed sender G28 on the V10-TDI-engine ...

a) sends its signals directly to both engine control units.

b) sends its signals to engine control unit 1 J623 and these are then passed on to engine control unit 2 J624 via an internal CAN databus.

c) sends its signals to engine control unit 1 J623 and these are then passed on to engine control unit 2 J624 via a separate cable.

Test your knowledgeAnswers

1. a, c; 2. a, b; 3. c; 4. c; 5. a, c; 6. a, b; 7. b, c; 8. c

51

Notes

Service.

For internal use only. © VOLKSWAGEN AG, Wolfsburg

All rights reserved. Technical specifications subject to change without notice.

000.2811.24.20 Technical status: 11/02

❀ This paper is produced from

non-chlorine-bleached pulp.

304